Segment:
Dual-sport / Enduro motorcycle
Target Audience:
Riders seeking a robust, reliable, and capable machine for both on-road commuting and off-road adventure riding.
Key Competitors:
Honda XR series, Suzuki DR series, KTM EXC series, Husqvarna TE series (of similar displacement and era).
Features:
Torquey single-cylinder engine, capable suspension, durable construction, electric start (RE model), versatile for various terrains.
Engine:
Complete engine overhaul, top-end rebuild, bottom-end inspection, valve adjustment, carburetor tuning, cooling system.
Transmission:
Gearbox disassembly, inspection, lubrication, clutch service, shift mechanism.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), ignition system (CDI, spark plugs), starter motor, lighting, switches, fuses.
Fuel System:
Carburetor identification and servicing (likely Mikuni VM34 or similar), fuel pump (if applicable), fuel lines, petcock.
Suspension:
Front fork (KYB or similar) disassembly, seal replacement, oil level/viscosity, rear shock absorber service, linkage lubrication.
Brakes:
Front and rear brake system service, caliper overhaul, master cylinder service, brake fluid replacement, pad replacement, disc inspection.
Cooling System:
Radiator service, coolant replacement, thermostat operation, fan operation (if equipped).
Exhaust System:
Muffler and header pipe inspection, gasket replacement.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fuel tank, fenders.
Wheels And Tires:
Wheel bearing inspection and replacement, spoke tensioning, tire mounting and balancing, recommended tire pressures.
Maintenance:
Routine checks, oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement, brake bleeding.
Troubleshooting:
Diagnosing common starting issues, engine performance problems, electrical faults, and suspension/brake concerns with symptom-based guides.
Repair:
Step-by-step instructions for component disassembly, repair, reassembly, and adjustment for all major vehicle systems.
Diagnostic Charts:
Detailed diagnostic flowcharts for identifying and resolving malfunctions.
Technical Specifications:
Torque specifications for all fasteners, engine clearances, fluid capacities, electrical resistance values, and performance data.
Wiring Diagrams:
Comprehensive and detailed wiring schematics for all electrical components.
Depth:
Comprehensive from basic owner maintenance to full engine and transmission rebuilds, including electrical diagnostics.
Diagnostic Level:
Advanced, covering component testing and symptom analysis.
Rebuild Scope:
Full engine, gearbox, and suspension component rebuilds.
Format Details:
Likely PDF, optimized for digital viewing and printing. Searchable text is a common feature of quality digital manuals.
Quality:
If printed, expect clear diagrams, legible text, and professional binding. For digital, high-resolution scans are standard.
Type:
N/A for digital format; typically comb-bound or perfect-bound if printed.
Type:
N/A for digital format; if printed, often on durable, glossy paper suitable for workshop environments.
Engine Type:
4-stroke, SOHC, air-cooled, single-cylinder
Displacement:
595 cc (approx.)
Bore X Stroke:
97.0 mm x 80.0 mm (approx.)
Compression Ratio:
9.5:1 (typical for this era and engine type)
Valve Train:
SOHC, 4 valves
Lubrication:
Wet sump (likely)
Horsepower:
Approx. 40-45 HP (at crank, figures vary by market and tuning)
Torque:
Approx. 45-50 Nm (at crank, figures vary by market and tuning)
Carburetor:
Single Mikuni VM34 or similar flat-slide carburetor.
Fuel Capacity:
Approx. 10-13 Liters (model dependent)
Ignition System:
CDI (Capacitor Discharge Ignition)
Starter:
Electric Start (RE model), Kick Start (back-up on some variants, or primary on non-RE)
Oil Change:
Every 3,000-5,000 km or annually. Refer to manual for exact mileage and time recommendations.
Valve Check:
Every 10,000-15,000 km. Crucial for maintaining performance and preventing damage.
Chain Maintenance:
Lubricate and adjust every 500-1000 km or after washing/wet riding. Replace chain and sprockets as a set when worn.
Air Filter Cleaning:
Every 5,000-10,000 km depending on riding conditions. Clean or replace.
Engine Oil:
Yamalube 10W-40 or equivalent API SG or higher motorcycle-specific oil. Capacity approx. 2.5-3.0 Liters with filter change.
Fork Oil:
Yamaha Fork Oil G10 or equivalent (e.g., Motul Fork Oil Expert 10W). Specific level and volume detailed in manual.
Brake Fluid:
DOT 4 recommended. Replace every 2 years or as specified.
Coolant:
50/50 mix of distilled water and ethylene glycol-based antifreeze. Use Yamaha Coolant or equivalent.
Common Issues:
Carburetor jetting can be sensitive to altitude and modifications. Valve seat wear over very high mileage. Suspension seals can degrade with age. Stator or regulator/rectifier failure (common on many bikes of this era).
